Transformer



Jan. 7, 1947. J. M. WILSON TRANSFORMER Filed May 15, 1942 3 Sheets-Sheet1 INVENTOR.

John M. Wilson Y zz wzwb ATTORNEY Jan. 7, 1947. J. M. WILSON 2,413,897

' TRANSFORMER Filed May 15, 1942 3 Sheets-Sheet 2 Jan. 7, 1947. w o2,413,897

TRANSFORMER Filed May 15, 1942 S Sheets-Sheet 3 INVENTOK John M. WilsonATTORNEY o a transformer of Patented Jan. 7, 1947 John M. Wilson,

Minneapolis,

Minneapolis, Minn., Minneapolis-Honeywell Regulator Minn., a corporationof assignor to Company, Delaware Application May 15, 1942, Serial No.443,101 14 Claims. (Cl. 175-361) This invention relates to transformersbut more particularly to improvements therein providing increasedeconomies in the construction of parts, facilitating the easeof assemblyof the parts, and generally providing greater utility in transformersnot heretofore known in the art.

A broad object of this invention is to provide extremely simpleconstruction of which various parts may readily be interchanged oraltered whereby the same transformer may be utilized for a'multiplicityof transformer purposes.

An important object of this invention is to provide a-simple core andwinding assembly, an expeditious method of assembling the same, and anovel clamping meansfor holding the parts in assembled relation.

Another objectof this invention is to provide a novel anchor plate forthe winding lead wires whereby the electrical connections between thelead wires and the winding are relieved of stresses andstrains exertedupon the lead wires.

A further object is to provide a housing for the core and windingassembly of this invention having means formed therein for retaining theassembly in a predetermined position in the housing, and having partswhich may be simply altered and/or readily interchanged whereby thetransformer may be utilized for various transformer mountings andcircuit connections.

A still further object of this invention is to provide a combinationtransformer and outlet box in which the casing of the transformer isformed in such a manner as to provide an outlet box at each end of thetransformer.

Still other objects are those inherent in or implied from the novelconstruction, combination, and arrangement of parts not specificallyrecited herein above which will become manifest upon reading thefollowing specification, reference being had to the attached drawings inwhich Figure 1 is a face view of one of the core laminations used in thetransformer of this invention,

Figure 2 is a perspective view of the core, winding, and clamping meansof the transformer illustrating the assembled,

Figure 3 is a cross-sectional view of the transformer shown in Figure 5,being viewed along the lines 3-3 of Fig. 5,

Figure 4 is another cross-sectional view of the transformer shown inFigure 5, being, viewed along the lines 4-4 of Figure 5,

Figure 5 is an elevational view of one assemmanner in which the same are.alternate combined cover Figure '7 is a right side elevational view ofthe transformer shown in Figure 6,

' Figure 8 is an elevational view of a third assembled form which thetransformer might take, again portions of the casing being broken awayto illustrate the construction and assembly,

Figure 9 is a right side elevational view transformer shown in Figure 8,

Figure '10 is a reduced combined cover and mounting plate which may ofthe and mounting plate which may be used on the transformer of thisinvention,

Figure 12 is a face the. transformer through 9, 13 and 14,e v

Figure 13 is an elevational view of a fourth alternate assembled formwhich the transformer of this invention might take, portions of thecasing being broken away to better disclose the particular constructionand assembly,

Figure 14 is a right side elevational view of the transformer shown inFigure 13,

Figure 15 is an elevational view of a combined transformer and outletbox which embodies several of the features of this invention, portionsof the casing being broken away to illustrate the construction,

Figure 16 is a left side elevational view of the transformer shown inFigure 15.

Referring first toFigures 3, 4 and 5, the numeral l9 generallydesignates a transformer which comprises a core and winding assemblygenerally indicated by thenumeral 20 and a housing therefor, generallydesignated by the numeral 2i.

The core and winding assembly comprises a primary and secondary winding22 and 23 respecview of a development of easing shown in Figures 3tively, carried by a winding leg 24 of a laminated window type core. Thestacked laminations of the leg 24 are pressed into the stackedlaminations of the yoke portion 25 of the core, the laminations beingheld in stacked relation and in pressed relation with respect to eachother by a U-shaped clamp, generally designated by the numeral 26.

' spectively,

' straddle the leg 24 24 and 25. As'will hereinafter be pointed out,

the leg portions 36'and 3| are bent over at a time when the laminationsare held under pressure. Consequently; the tendency of the laminationsto separate provides a frictional means for maintaining the clamp 26 inplace on the core.

In Figure 1, a core lamination is shown in. which the leg portion 24 isformed integrally with the yoke portion 25. As a matter of fact, theyoke and leg la out of the same sheet lamination, the two beingseparated along the dotted lines 32 and 33. Apertures 34 and-35 are alsopunched out of the sheet lamination at the lines 32 and 33 for purposesof providing alignment of the lamination portions in the assembly of thecore. It will be noted that the bight portion generally similar to 25having apertures with the apertures 34 and 35 of the laminations. Theleg portions 30 and 3| areprov-ided with indentations 38 and 39'whichalso coincide with the apertures 34 and 35 for a purposehereinafter to appear. V

In making a core and winding assembly 20, a plurality of corelaminations 24 and 25 are first blanked out. The laminations comprisingthe yoke 25 are then stacked in the clamp 26 which is preformed to theangular configuration as shown in Figure 2, the leg portions 36 and 3|being bent slightly inwardly. Withthe apertures 34, 35 of the corelaminations in alignment with the the laminations of the yoke vapertures 36, 31 of the clamp, the clamp and .yoke laminations areassembled on a jig 40,

guide pins 4| and 42 carried thereon, occupying the apertures 34, 35 and36, 31. The leg laminations 24 are next stacked and the windings 23, 22mounted thereon in any convenient manner. The windings and core legassembly is then mounted on the guide pins 4|, 42 and brought intoengagement with the yoke 25. A suitable pressure applying means (notshown) is then applied to the leg 24- forcing the laminationsthereofinto engagement with the laminations of theyoke 25. The arrangement ofthe pressure applying means is such that when the leg 24 and yoke 25 arecompletely engaged, pressure is applied to the laminations or both coreportions, and while the pressure is being applied, the le portions 3|]and 3| of the clamp 26 are bent over by any suitable means until theclamp takes the form as seen in Figure 5. The indentation 38 and 39permit the leg portions 36 and 3| to clear the guide pins and 42. Theassembly 26 is then conveniently removed'from the jig 46 by simplysliding the assembly oif of the guide pins 4| and 42.

The ends 43, 44 of the windings 22, 23 reare brought out to terminalboards 45 and 46 which may be identical, and may be formed of anysuitable insulating material. Each board 45, 46 is'inserted between oneend of the windings and the yoke 25, each being bifurcated to withthe-bifurcations 41 and 48 fitting snugly between the leg 24 and theyoke 25 as clearly seen in Figure 4. The ends of the windings are woundwith one or more turns about projections 49 on the boards 45, 46 andsoldered to suitable lead wires 50 and for the windings 22 and 23respectively. The lead wires 50 and 5| are securely anchored to theboards 53 and a cover 54 therefor.

ation portions are blanked.

21 of the clamp 26 is shaped 36 and 31 which coincide tions' between thewindings and lead wires of such stresses and strains.

The housing 2| comprises a box-shaped casing Referring to Figure 12, itwill be seen that the casing 53 is formed of 'a single cross-shapedsheet of metal, the center portion55-of which corresponds to the top ofthe casing and the arms 56, 51, 58 and 59 of which comprise the sides ofthe casing, the sides being bent down about the dotted lines 69, 6|, 62and 63 to form the box shape thereof.

The assembly 20 is retained in the casin 53 in a definite positiontherein by depressions 65 formed in the sides 56 and 51 which engage thesidesof the core yoke 25 as best seen in Figures 3 and 4. Itis to benoted that the casing 53 is formed in such a manner that the sides 55,56 and 51 engage the core. Consequently, the assembly20 can only bysliding the same between the depressions 65. It is to be further notedthat the clamp 26 is somewhat narrower than the width of the yoke 25 topermit the depressions 65 to engage the yoke. It is obvious that if thedepressions were extended adjacent the clamp 26, it would be impossibleto remove the casing because of the noncontinuity of the clamp on oneside of the core. It is further obvious that if the assembly 2| wererotated through in the plane of the depressions 65, as seen in Figure 3,the depressions 65 would extend adjacent the relatively rounded edges 66of the clamp 26 and thereby necessitate the use of much in the cover 54.The cover 54 is further provided with a number of apertures 19, by meansof which the transformers may be mounted to an outlet box. A furtheraperture 1| is provided through which the lead wires 5| may be drawn sothat the primary winding 22 may be connected into the line circuitsbrought into the outlet box. It is to be noted that the sides of thecasing 53 are substantially the same height as the assembly 20.Consequently, when the cover 54 is secured to the casing 53 the assembly20 is secured against any movement in the housing 2|.

A plate 13 is disposed adjacent the side 59 of the casing 53 and has aninternally threaded nipple 14 staked thereto through which the secondarylead wires 5| are drawn for connections to external circuits, The side59 is provided with an indentation 15 to accommodate the nipple 14. Theplate 13 is retained against the side 59 by depressions 16 similar tothe depressions 65 which are also formed in the casing sides 56 and-51.Thus, by this arrangement the secondary winding 23 may be connected to acircuit brought through standard conduit since the nipple 14 can beconnected to the conduit. A screw 11 is used to metallicallyconnecttheplate .13 to .thecasin'g side 59 to satisfy underwriters requirementswith be removed from the casing assembly 2|) from the respect toproviding a continuous ground for the sembly 20 and plate 13 areretained in the casing 53, that the connections to the windings mayconveniently be made while the plate 13 and assembly 20 are removed fromthe casing, thus facilitating the ease of attachment of the plate '88 tothe conduit.

In Figures 6, 7, 8, 9, 13 and 14 transformers are shown which aregenerally similar to the transformer IQ of Figure 5. Accordingly,wherever possible, similar reference characters will be used to indicatesimilar Darts.

Referring to Figures 6 and 7, the numeral it; generally designates atransformer which is the same as transformer l9 except that a panel l9,formed of any suitable insulation material, has been substituted for theplate 13 and the ends 98 .of the secondary winding 23 are connected toterminals 80 provided on the panel 19. The terminal board 46 is omittedand inserted in place thereof is a wedge 8| to assure a frictional fitof the primary terminal board 45 between the windings and the core asbefore. When desirable, a fuse 82 may be inserted in series with thesecondary winding as clearly seen in Figures 6 and '7.

In Figures 8 and 9 a transformer 83 is shown which differs from thetransformer i9 in that an externally threaded nipple M is staked to thecasing side 58 which may be provided with an aperture as indicated bythe dotted lines 85 in Figure 12. The transformer 89 may be mounted onan outlet box by mounting an outlet box cover plate 89, generallysimilar to the outlet box cover plate 52 of Figure 5, on the nipple 89,the same being secured thereto by a nut 87. The cover plate 89 isprevented from rotating relative to the casing 53 by a tongue and slotarrangement between the sides 56 and 51 of the casing 53 and the coverplate 86, the sides 56 and 51 having tongues 88 which enter slots in thecover plate 86 similar to the slots 89 of cover plate 52. a

It may be desirable to mount the transformer 83 on a wall or othersuitable support rather than on an outlet box. For this purpose, thetransformer 83 is'provided with a mounting bracket 89 which has slots 99similar to the slots 89 of the cover plate 54 by means of which it issecured to the casing 53 as in the case of the cover plate 59'. Thebracket 89 is also provided with additional apertures 9| by means ofwhich the transformer may conveniently be mounted on a wall or othersupport. When the mounting bracket 89 is used, both windings of thetransformer 83 are connected into circuits which are brought throughconduit. Accordingly, it is obvious that since the necessary connectionsbetween the conduit and the transformer may be made when the assembly 2|and the plate 73 are removed from the casing 53, such connections aregreatly facilitated by such removal.

. In Figures 13 and 14 a transformer 92 is shown which combines thefeatures of the transformers 18 and 83. Transformer 92 may be used withor without the outlet box cover plate 88, the primary lead wires 59either being connected to circuits in the outlet box or to circuitscarried through conduit connected with the nipple 84. The transformer 92is further provided with the panel 79 respective circuits whenv thecasing 95,

of transformer 18. In the transformer 92 however, the fuse 82 has beeneliminated to illustrate the construction when a fuse is not used.

' In Figures and 16 a combined outlet box and transformer 93 is shown inwhich the core and winding assembly is used and similarly retained in ahousing therefore as in the case of the foregoing transformers. Thehousing comprises a casing 94 which is formed of a single sheet of metalfolded to provide three sides of 96 and 91 and a cover 98 for the casingwhich is shaped and fastened similarly to the mounting bracket 89described in connection with transformers 83 and 92, conventional tongueand slot means generally indicated at 99 being used. The sides 96 and9'! carry depressions Hi9 which determine the position of the assembly29 in the casing 94 as in the case of the foregoing transformers.

The remaining casing sides for enclosing the assembly 28 comprise platesI 9| which are disposed in the housing midway between the assembly andthe ends of the casing and cover 98. The spaces between the ends of theplates l0! and the ends of the housing comprise outlet box compartments.The plates I [ll are retained in a definite position in the housing bydepressions I02 formed in the casin sides 96 and 91 and arranged on eachside of the plates in! as clearly seen in Figures 15and 16;, AperturesI03 are provided in' the plates llli through which the lead wires 50 and5| of the primary and secondary windings 22 and 29, respectively, aredrawn for connection with their respective circuits which may be drawninto the outlet box compartments through anyone of a number of aperturesI94 formed upon removal of the provided in the casing sides 95, 96 and91. The casing side 95 and the cover 98 are provided with bent portionsI06 and I9! respectively, to which cover plates 18 for the outlet boxesmay be secured, suitable attaching screws I89 beingused for thispurpose.

From the foregoing, it is now apparent that I have provided transformerswhich are extremely simple in construction and well adaptable for amultiplicity of transformer mountings and circuit connections. The wideutility of these transformers is made possible, largely, by virtue ofthe novel means for retaining the core and windin assembly in thehousing therefor, since by this arrangement, other sides of the housingare available to accommodate various circuit connections and toaccommodate various interchangeability of parts to make such circuitconnection variations possible. It has also been seen how theconstruction of the casing has made alternative mountings for thetransformers possible.

While I have disclosed several preferred embodiments of my invention, itis to be understood that the disclosures were for purposes ofillustrationonly and not to be considered in a limof stacked laminationsand a winding surrounding the same and holding said laminationstogether, said yokes and winding leg being so knock-out plugs I05 shapedthat the winding leg may be pressed into said yokes for holding saidparts together, and clamping means comprising a substantially U- shapedmember including bent over portions pressing laminations of saidyokestogether and holding the same in pressed relation whereby chored to saiddevice thereby relieving said electrical connections of stresses andstrains exerted upon said lead wire.

3. In combination, an electrical device havin a winding, 9, combinedterminal and anchor board secured to said device, a lead wire forconnection to an end of said winding, means for electrically connectingsaid lead wire to the end of said winding on said board, and a pluralityof apertures formed in said board for receiving said lead wire in aseries of half turns whereby said lead wire is anchored to said devicethereby relieving said electrical connections of stresses and strainsexerted uponsaid lead wire.

4. A transformer comprising a laminated core including a plurality ofinterfitting sections, a winding on one of said sections, clamping meanscomprising a substantially U-shaped member for holding said sections inassembled relation, a casing for said-core and winding, said casingbeing formed of sheet stock in such a manner that three sides thereofengage said core, and means comprising extrusions formed in two of saidthree sides for engaging and retaining said core insaidvcasing in apredetermined position therein, and said clamping means being formed insuch a manner as-to permit an insertion of said core into said casingbetween' said retaining means. I

5. Aitransformer comprising a. care including a plurality ofinterfitting sections, a'winding on one of said sections, clamping meansfor holding said sections in assembled relation, lead wires connected tosaid winding, an anchor plate for said lead wires inserted between saidwinding and core, said clamping means being formed in such a manner asto permit said anchor plate to be inserted between said winding andcore, a housing for enclosing said core and winding, means formed insaid housing engageable with said core for retaining the same in thehousing in a predetermined position therein, said clamping means beingformed in such a manner as to permit an insertion of said core intosaid. housing between said retaining means, and aperture means providedin said housing through which said lead wires may be drawn.

6, A transformer comprising a winding and said member being for thewinding, and standard coupling for connection "to standard conduit,secured to I said member through which said lead wires may as toaccommodate said electrical conductor means. I

l. A transformer comprising a winding and core assembly. a housing forthe assembly, means formed in the housing for retaining the assembly inthe housing in a predetermined position therein, a member removablyassociated with the housing and disposed adjacent a first side thereof,means formed. in a second and third side for retaining said memberadjacent said first side, v insertable into said housingfbetween saidfirst side and the retaining means formed in said second and thirdsides, lead wires means be drawn, said first side being formed in such amanner as to accommodate said coupling means.

8. A transformer comprising a core and winding assembly, a panel,terminals on the panel for connections with the winding, a

. assembly and panel, said panel being disposed -,iormed in such amanner as of said windings, one

core assembly, a. housing for the assembly, means formed in the housingfor retaining the assembly in the housing in a predetermined positiontherein, a member removably associated with the housing and disposedadjacent. a first side thereof, means formed in a second and third sidefor retaining said member adjacent said first side,

electrical conductor means for connecting thewinding'to an externalcircuit, and said first side and said member being formed in such amanner adjacent one side of the housing, means formed in second andthird sides of the housing for retaining the assembly and panel therein,said assembly and panel being insertable into andremovable from thehousing by sliding'the same between said retaining means whereby thewinding may be secured tothe terminals and the assembly and'panelinserted "into thehousing as a unit, and said first side being formed insuch a manner whereby external made with said terminals whenthetransformer is in an assembled condition.

9. A transformer comprising-a plurality of windings, a core for saidwindings, a housing for enclosing said windings and core, means forretainingsaidwindings and core-in 'said housing, electrical conductormeans for connecting said windings with external circuits, said housingcomprising a first pair of sides each of which is formed in such amanner as to accommodate the conductor means for one of said windings,one.

of said first pair of-sides being an outlet box cover and having anaperture the conductor means for one of said windings may be drawn, vcomprising a member associated, with said housing, and means formed in asecond pair of sides for engaging said member and retaining the same insaid housing in a predetermined manner whereby said member may beinserted or removed from said housing by sliding the same between saidformed means and said housing;

10. A transformer comprising a plurality -of windings, a core for saidwindings, a housing for enclosing said windings and core, 'means forretaining said windings and core in said housin electrical conductormeans for connecting'said windings with external circuits, said housingcomprising wflrst pair of sides each of whichis to accommodate theconductor means for one of said first pair of sides having a standardthreaded nipple secured thereto, through which the conductor means ofone of said windings may be drawn, an outlet box cover secured to thenipple by means of which the transformer may be mounted on a standardoutlet box, said housing comprising a third side which serves as amounting bracket by means of which the transformer may be mounted on asuitable support, said housing comprising fourth and fifth sides inengagement with-said outlet box cover and said third side, and meanscarried by said fourth and housing tor the connections may be a thereinthrough which i the other of said-first pair of sides taining saidwindings and core in ;;nipple secured thereto through boxes," the otheror said first prising a member removably consisting of spaced memberincluding bent over 'ingflthe. leg and its d ss in operable relaoutletbox cover and said housing.

11. A transformer comprising a plurality oi windings. a core for saidwindings. a housing for enclosingsaid windings and core, means forresaid housing. electrical conductor means for connecting said withexternal circuits, said housing comprising a first pair of sides each ofwhich is formed-in such a manner as to accommodate the conductor meansfor one 01' said windings, one of said first pair of sides having astandard threaded which the con.-

ductormeans' or one of said windings may be drawn and bymeans of whichthe transformer maybe secured to standard conduit and outlet pair ofsides comassociated with said housingrsaid member having'a standardnipple secured thereto through which the conductor means for another ofsaid windings may be drawn and by means of which the transformer may beconnected to standard conduit, and means formed in said housing forretaining said membet in a predetermined position therein;

12. In combination, including a casing, a transformer spaced in the.casing, the transiormer integrally connected yokes comprising aplurality oi laminations and an interiltting leg portion comprising aplurality of laminations' having windings for holding the laminationstogether. and a U-shaped clamping portions for holdtion to said Yokes.

' the ends 01 the other 86 13. In combination, including a "casing, atransformer spaced in the casing, the transformer consisting of spacedintegrally connected yokes comprising a plurality of laminations,aperture means in each of the yokes, an interfitting leg portioncomprising a plurality of laminations having windings for holding thelaminations together, aperture means in at least two sides of the legportion, a member having bent over portions with aperturestherein forholding the leg and its win'dings in operable relation to said yokes,and when the, clamping member is in holding relation to said transformerthe apertures of the clamping member are aligned with the apertures inthe yokes and the legportions of the transi'ormer.

14. A transformer comprising windings and a core assembly, clampingmeans for holding the winding and core assembly in assembled relation,electrical conductor means connected with one of the windings, means foranchoring the conductor means associated with the one winding; a housingfor the assembly, one side of the housing having outlet means for theconductor means, a member removably associated with the housing, meanson second and third sides of the housing for retaining the windings andcore assembly in a predetermined positio'nin said housing, means on thesaid second and third sides of the housing for positioning the removablemember adjacent a fourth side of the ciated with the removable member sothat conductor means may be electrically connected with of saidwindings.

JOHN M. WILSON.

U-shaped clamping housing. and means asso-e

